Adjustable interlacing of drying rollers in a print system

ABSTRACT

Systems and methods for adjustable interlacing of drying rollers in a print system. One system is an apparatus that includes first rollers that conduct heat from a heat source, and dry a web of print media as the web travels over a front side of the first rollers in a first direction. A last roller of the first rollers turns the web in a second direction. The apparatus also includes second rollers disposed a distance above the first rollers and that transport the web in the second direction. The apparatus further includes a movement mechanism that reduces the distance between the second rollers and the first rollers to cause the second rollers to occupy spaces between the first rollers so that the web traveling in the second direction contacts a back side of the first rollers to further dry the web.

RELATED APPLICATIONS

This document is a continuation of co-pending U.S. patent applicationSer. No. 14/693,020 (filed on Apr. 22, 2015) titled, “ADJUSTABLEINTERLACING OF DRYING ROLLERS IN A PRINT SYSTEM,” which is herebyincorporated by reference.

FIELD OF THE INVENTION

The invention relates to the field of printing systems, and inparticular, to print drying systems.

BACKGROUND

Businesses or other entities having a need for volume printing typicallyuse a production printer capable of printing hundreds of pages perminute. A web of print media, such as paper, is stored the form of alarge roll and unraveled as a continuous sheet. During printing, the webis quickly passed underneath printheads which discharge small drops ofink at particular intervals to form pixel images on the web. The web maythen be dried and cut to produce a printed product.

In dryers that apply a great deal of heat over a short period of time,it remains a problem to ensure that the print media is properly dried.Too much heat can cause the media to char or burn, while too little heatcan result in ink smearing or offsetting that reduces the print qualityof jobs. Moreover, other problems in the dryer may occur such as curlingor wrinkling of the media due to non-uniform stresses applied to themedia during high rates of thermal exchange. Such problems may beamplified as the paper cools in an uncontrolled and non-uniform manner.

SUMMARY

Embodiments described herein provide for adjustable interlacing ofdrying rollers in a print system. A series of rollers transport a web ofmedia as the media travels in a drying system. One or more of therollers may be heated to a desired temperature for drying ink recentlyapplied to the media. A first set of rollers transport the web in afirst direction, and a second set of rollers transport the web in asecond direction, generally opposite to the first direction. The rollersare adjustable such that the first set of rollers and second set ofrollers may interlace. When interlaced, the web travels in the seconddirection in a weaving pattern between the first set of rollers and thesecond set of rollers to further dry the web as it travels in the seconddirection.

One embodiment is an apparatus that includes first rollers, at least oneof which is configured to conduct heat from a heat source, and dry a webof print media as the web travels over a front side of the first rollersin a first direction. A last roller of the first rollers turns the webin a second direction. The apparatus also includes second rollersdisposed a distance above the first rollers and that transport the webin the second direction. The apparatus further includes a movementmechanism that reduces the distance between the second rollers and thefirst rollers to cause the second rollers to occupy spaces between thefirst rollers so that the web traveling in the second direction contactsa back side of the first rollers to further dry the web.

Another embodiment is a system that includes a dryer of a print system.The dryer includes first rollers configured to transport a web of printmedia along a first path. At least one of the first rollers isconfigured to heat the web to dry ink applied on the web. The dryer alsoincludes second rollers configured to transport the web of print mediaalong a second path above the first path. The system also includes acontroller configured to direct a movement mechanism to adjust thesecond rollers with respect to the first rollers in a directionperpendicular to a traveling direction of the web.

The above summary provides a basic understanding of some aspects of thespecification. This summary is not an extensive overview of thespecification. It is not intended to identify key or critical elementsof the specification nor to delineate any scope of particularembodiments of the specification, or any scope of the claims. Its solepurpose is to present some concepts of the specification in a simplifiedform as a prelude to the more detailed description that is presentedlater. Other exemplary embodiments (e.g., methods and computer-readablemedia relating to the foregoing embodiments) may be described below.

DESCRIPTION OF THE DRAWINGS

Some embodiments of the present invention are now described, by way ofexample only, and with reference to the accompanying drawings. The samereference number represents the same element or the same type of elementon all drawings.

FIG. 1 illustrates an exemplary continuous-forms printing system.

FIG. 2 illustrates a drying system in an exemplary embodiment.

FIG. 3 illustrates a side view of a drying system with a series ofrollers in an exemplary embodiment.

FIG. 4 illustrates a side view of a drying system with a series ofrollers in an interlaced configuration in an exemplary embodiment.

FIG. 5A illustrates rollers of a drying system in a non-interlacedposition in an exemplary embodiment.

FIG. 5B illustrates rollers of a drying system in a slightly interlacedposition an exemplary embodiment.

FIG. 5C illustrates rollers of a drying system in a substantiallyinterlaced position in an exemplary embodiment.

FIG. 6 illustrates a side view of a drying system with a series ofrollers in another exemplary embodiment.

FIG. 7 illustrates a perspective view of a drying system with a seriesof non-interlaced rollers in another exemplary embodiment.

FIG. 8 illustrates a perspective view of a drying system with a seriesof interlaced rollers for adjusting the drying of a web in anotherexemplary embodiment.

FIG. 9 illustrates a perspective view of a drying system with a seriesof non-interlaced rollers in another exemplary embodiment.

FIG. 10 illustrates a perspective view of a drying system with a seriesof interlaced rollers in another exemplary embodiment.

DETAILED DESCRIPTION

The figures and the following description illustrate specific exemplaryembodiments. It will thus be appreciated that those skilled in the artwill be able to devise various arrangements that, although notexplicitly described or shown herein, embody the principles of theembodiments and are included within the scope of the embodiments.Furthermore, any examples described herein are intended to aid inunderstanding the principles of the embodiments, and are to be construedas being without limitation to such specifically recited examples andconditions. As a result, the inventive concept(s) is not limited to thespecific embodiments or examples described below, but by the claims andtheir equivalents.

FIG. 1 illustrates an exemplary continuous-forms printing system 100.Printing system 100 includes production printer 110, which is configuredto apply ink onto a web 120 of continuous-form print media (e.g.,paper). As used herein, the word “ink” is used to refer to any suitablemarking fluid (e.g., aqueous inks, oil-based paints, etc.). Printer 110may comprise an inkjet printer that applies colored inks, such as Cyan(C), Magenta (M), Yellow (Y), Key (K) black, white, or clear inks. Theink applied by printer 110 onto web 120 is wet, meaning that the ink maysmear if it is not dried before further processing. One or more rollers130 position web 120 as it travels through printing system 100. Printingsystem 100 also includes drying system 140, which is any system,apparatus, device, or component operable to dry ink applied to web 120.

FIG. 2 illustrates a drying system 140 in an exemplary embodiment.Drying system 140 includes a drum 210 and a radiant energy source 220.During operation, web 120 is marked with ink by a print engine, entersdrying system 140, and wraps around an outer surface of rotating drum210, which is heated to a desired temperature via heat transfer ofradiant energy source 220. Radiant energy source 220 is any system,component, device, or combination thereof operable to radiate heat todrum 210. One example of a radiant energy source 220 is an array of heatlamps that emit infrared (IR) or near-infrared (NIR) energy and heat.

Conventional drying systems typically include one large drying drum fordrying ink applied to the web. In these systems, there is a relativelylow degree of control for adjusting temperatures applied to the web ofprint media because the circumferential section of the drum whichcontacts the web is constant. Previous systems are thus limited toadjusting the output of the energy source to increase or decrease thetemperature of the drum and the heat applied to the web.

Drying system 140 is therefore enhanced with a series of rollers forincreased control of drying temperatures applied to web 120. FIG. 3illustrates a side view of a series of rollers for drying web 120 in anexemplary embodiment. After printing, web 120 enters drying system 140with a marked side 122 that is wet with an applied ink, and an unmarkedside 124 that does not have wet ink. Web 120 is tensioned over a seriesof rollers 310-326 which rotate for transportation of web 120 in dryingsystem 140 in the arrow direction shown in FIG. 3. One or more rollers310-326 is heated (e.g., with radiant energy source 220, not shown inFIG. 3) for drying ink applied to web 120.

In general, the individual size of rollers 310-326 is small incomparison to the single large drum dryer of that previously described.Rollers 310-326 may collectively occupy a space with a smaller footprintthan that of a large drum dryer. Moreover, as will be apparent in thedescription to follow, drying system 140 may include variousarrangements and numbers of rollers 310-326 for precise drying controlof web 120 in a compact space within drying system 140.

As shown in FIG. 3, rollers 310-326 are generally comprised of a firstseries of rollers 310-314 and a second series of rollers 320-326. Thefirst series of rollers 310-314 receive web 120 at the entrance ofdrying system 140 and transport web 120 in a first direction (e.g., leftto right in FIG. 3). A turning roller 314, which is the last to receiveweb 120 in the first series of rollers 310-314, reverses the travellingdirection of web 120. The second series of rollers 320-326 receive web120 from turning roller 314 and transport web 120 in a second direction(e.g., right to left in FIG. 3), which is opposite to the firstdirection. An exit roller 326, which is the last to receive web 120 inthe second series of rollers 320-326, may turn the travelling directionweb 120 before it exits drying system 140.

The second series of rollers 320-326 are generally disposed in dryingsystem 140 above the first series of rollers 310-314. As such, as web120 travels in the second direction (e.g., right to left in FIG. 3), web120 travels above but does not contact the first series of rollers310-314. For increased control in drying web 120, drying system 140 maybe further enhanced to interlace the first series of rollers 310-314 andthe second series of rollers 320-326.

FIG. 4 illustrates a side view of a drying system with a series ofrollers in an interlaced configuration in an exemplary embodiment. Whenrollers 310-326 of drying system 140 are in the interlacedconfiguration, web 120 contacts the first series of rollers 310-314 asit travels in the second direction. Drying system 140 is thereforeoperable to vary the amount of heated surface contact of web 120.

Interlacing of rollers 310-326 refers to a positional relationshipbetween roller(s) that rotate in opposite direction as web 120 travelsfrom an entrance to an exit of drying system 140. Drying system 140 isconfigured to adjust these positional relationships to cause acorresponding adjustment in heat applied to web 120. Thus, drying system140 may include a movement mechanism 450 that is any system, device,apparatus, or combination thereof to adjust a distance of one or more ofthe first series of rollers 310-314 relative to one or more of thesecond series of rollers 320-326. Examples of movement mechanism 450include, but is not limited to, a pneumatic device, a hydraulic device,a motor, an electric linear actuator, etc. Movement mechanism 450 may bemechanically coupled to the first series of rollers 310-314, the secondseries of rollers 320-326, or both.

FIGS. 5A-5C illustrate various positions of oppositely rotating rollersin drying system 140. Suppose, for example, that adjacent rollers310-312 are heated and rotate in a counter-clockwise direction fortransportation of web 120 in a first direction through drying system140. Suppose further that roller 322 rotates in a clockwise directionfor transportation of web 120 in a second direction through dryingsystem 140. The amount of interlacing between oppositely rotatingrollers may be described with respect to a boundary 311 that connects toadjacent rollers 310-312. The boundary 311 may be thought of as atangential line that connects to outer circumferences of two adjacentrollers operable to transport web 120 one after the other in the samedirection, the line being orthogonal to each of the radiuses of theadjacent rollers.

FIG. 5A illustrates rollers of a drying system in a non-interlacedposition in an exemplary embodiment. In the non-interlaced position,roller 322 is generally disposed some distance above the boundary 311.Therefore, roller 322 does not press web 120 to contact adjacent rollers310-312 as web 120 travels in the second direction.

FIG. 5B illustrates rollers of a drying system in a slightly interlacedposition an exemplary embodiment. The rollers may be referred to asbeing in an interlaced position when a roller that rotates in dryingsystem 140 in one direction (e.g., roller 322) intersects or crosses theboundary line 311 of a roller that rotates in drying system 140 inanother direction (e.g., rollers 310-312) or vice versa. In theinterlaced position, roller 322 presses web 120 to contact adjacentrollers 310-312 as web 120 travels in the second direction.

Drying system 140 is configured to control the amount of heat applied toweb 120 as it travels in the second direction by controlling the amountby which an oppositely rotating roller crosses past the boundary line311. In the slightly interlaced position as shown in FIG. 5B, roller 322is moved a relatively small distance past the boundary line 311 and intospaces between rollers 310-312. Thus, a relatively small circumferentialportion of rollers 310-312 contact web 120 as it travels in the seconddirection and a correspondingly small increase of heat is applied to web120 in drying system 140.

FIG. 5C illustrates rollers of a drying system in a substantiallyinterlaced position in an exemplary embodiment. In this position, roller322 is moved a relatively large distance past the boundary line 311 andinto spaces between rollers 310-312. As web 120 travels in the seconddirection, the position of roller 322 presses web 120 downward to causeit to wrap around a larger circumferential portion of rollers 310-312for increased heat applied to web 120.

Thus, for a relatively large increase in heat applied to web 120, dryingsystem 140 may interlace multiple rollers by moving rollers that rotateone direction (e.g., the second series of rollers 320-324) to occupyspaces between multiple rollers that rotate in another direction (e.g.,the first series of rollers 310-314) at relatively large distances pastthe interlacing boundary lines for an increased wrap angle and thereforeincreased heated contact between web 120 and the back side of the firstseries of rollers 310-314. Alternatively, for a smaller increase in heatapplied to web 120, drying system 140 may interlace fewer rollers and/orinterlace rollers at relatively small distances past the interlacingboundary lines.

Printing system 100 and/or drying system 140 may further include acontroller for directing the movement mechanism 450 to position rollersbased on drying conditions, web properties, ink amounts, operator input,etc. Printing system 100 or drying system 140 may also include agraphical user interface to receive operator input or instructions fordirecting the controller. The graphical user may display an amount ofinterlacing between one or more rollers of drying system 140 and/ordisplay a current status indicative of whether rollers in drying system140 are interlaced or non-interlaced.

The controller may direct movement mechanism 450 to disengage one ormore rollers of drying system 140 to a non-interlaced positionresponsive to input, instructions, or a determination that maintenanceprocedures are to be performed on drying system (e.g., paper threadingand roller cleaning), that transportation of the web 120 is to halt,that a period of non-printing is to occur (e.g., to prevent curling ofweb 120 when web is stationary between interlaced rollers), or thatadditional drying of web 120 is unnecessary. Alternatively oradditionally, the controller may direct movement mechanism to engage oneor more rollers of drying system 140 to an interlaced position inresponse to operator input, instructions, or a determination thatincreased drying of web 120 is desirable. For example, controller maydirect movement mechanism 450 to adjust the wrap angle or the amount ofinterlacing between one or more rollers to cause a correspondingincrease or decrease in heat applied to web 120 in response toinstructions received at the graphical user interface.

FIG. 6 is a side view of drying system 140 with a series of rollers inanother exemplary embodiment. FIG. 6 shows that rollers (e.g., rollers302-328) of drying system 140 may be configured to transport web 120over several heat-adjustable surfaces in a compact space. A first seriesof rollers 302-314 rotate counter-clockwise and are disposed in dryingsystem 140 in a semi-circular pattern. A second series of rollers316-328 rotate clockwise and are disposed in a semi-circular patternabove the first series of rollers 302-314. One or more rollers 302-328may have an associated reflective material 330 coupled therewith ordisposed nearby to reflect radiated heat back toward web 120 forincreased heating efficiency.

Drying system 140 is configured to adjust the relative positions betweenone or more the first series of rollers 302-314 and one or more of thesecond series of rollers 316-328 to various interlacing ornon-interlacing positions for optimal drying control of web 120. FIG. 7is a perspective view of drying system 140 with a series ofnon-interlaced rollers in another exemplary embodiment. FIG. 8 is aperspective view of drying system 140 with a series of interlacedrollers in another exemplary embodiment.

Since rollers 302-328 of FIGS. 6-8 are disposed in drying system 140 incurved patterns, drying system 140 may be configured to adjustindividual interlacing positions of rollers in various directions thatare perpendicular to the curved travelling path of web 120. For example,at least some of the second series of rollers 316-328 may be offset fromthe first series of rollers 302-314 with respect to a direction parallelwith the travelling direction of web 120. Drying system 140 adjustscontact drying of web 120 by moving the offset, oppositely rotatingrollers into spaces between one another in a direction perpendicular tothe travelling direction of web 120.

When not interlaced, the second series of rollers 316-328 are disposed adistance from the first series of rollers 302-314 in a directionorthogonal to the travelling direction of web 120 when drying system140. As web enters drying system 140, the unmarked side 124 of web 120contacts a portion of the outer circumference of each of the firstseries of rollers 302-314 which transport web 120 in a forward curvedpath. The circumferential portion of each of the first series of rollers302-314 which contact web 120 in the forward direction may be referredto herein as a front side of rollers 310-314. The second series ofrollers 316-328 transport web 120 in a reverse curved path above thefirst series of rollers 302-314.

Though ink applied to the marked side 122 of web 120 may be sufficientlydry so as not to smear by the time it reaches and contacts the secondseries of rollers 316-328, it may be desirable for a number of reasonsto further transfer heat to web 120 for sufficient print quality. Toadjust the amount of heat applied to web 120, drying system 140interlaces one or more rollers 302-328 as described above. As such, amovement mechanism 450 may increase or decrease the distance between oneor more of the second series of rollers 316-328 and one or more of thefirst series of rollers 302-314.

When interlaced, the distance between the second series of rollers316-328 and the first series of rollers 302-314 is decreased. Theunmarked side 124 of web 120 contacts a portion of the outercircumference of each of the first series of rollers 302-314 as web 120travels generally in the reverse direction but which now interleaves ina zigzag pattern between the second series of rollers 316-328 and thefirst series of rollers 302-314. The circumferential portion of each ofthe first series of rollers 310-314 which contact web 120 in the reversedirection may be referred to herein as a back side of rollers 310-314.

Thus, when drying system 140 is configured with interlaced rollers, web120 is heated via front side contact of each of the first series ofrollers 302-314 in the forward direction, and web 120 is further heatedvia contact with the back side of each of the first series of rollers302-314 as web 120 travels in the reverse direction. Thus, the totalamount of contact between web 120 and the first series of rollers302-314 in drying system 140 is increased and the total heat applied toweb 120 is therefore also increased in comparison to when drying system140 is configured with non-interlaced rollers.

FIG. 9 is a perspective view of drying system 140 with a series ofrollers in yet another exemplary embodiment. FIG. 10 is a perspectiveview of drying system 140 with a series of rollers in an interlacedposition in yet another exemplary embodiment. As shown in FIGS. 9-10,rollers 901-939 are positioned in drying system 140 in a spiral pattern.The spiral pattern of rollers 901-939 increases the number of heatcontactable surfaces for web 120 in drying system 140 in a relativelycompact space.

Suppose, for example, that the first series of rollers 901-921 areheated and transport web 120 in a forward direction along a first spiralpath. Suppose further that the second series of rollers 922-939 are atambient temperature and transport web 120 in a reverse direction along asecond spiral path inside the first spiral path. As web 120 entersdrying system 140 and travels in the forward direction, a high degree ofcontrol for drying web 120 is possible (e.g., in comparison to a singledrum dryer) since surfaces of each of the first series of rollers901-921 may be heated separately to various temperatures. No furtherheat is applied to web 120 via contact between web 120 and the firstseries of rollers 901-921 after web 120 turns directions at roller 921to travel in the reverse direction when rollers 901-939 are in anon-interlaced configuration. Drying system 140 may adjust theengagement amount between the first series of rollers 901-921 and thesecond series of rollers 922-939 in a direction orthogonal to the spiralpattern to cause a corresponding adjustment in heat transferred to web120 via the first series of rollers 901-921.

Rollers of drying system 140 may transfer thermal energy in a variety ofconfigurations. For instance, rollers may be heated, cooled, or ambientin temperature in any number of combinations to provide desiredconditioning of web 120. Also, rollers of drying system 140 may bedriven and/or idle in any number of configurations. Heated rollers mayinclude a radiant energy source, such as radiant energy source 220,disposed inside a hollow circumference of rollers 310-326 and/ordisposed outside an external surface of rollers 310-326. In oneembodiment, one or more of the first series of rollers are heated andone or more of the second series of rollers are ambient or cooled. Thecontroller that directs movement mechanism 450 may be configured withinformation regarding which rollers are heated, ambient, or cooled tocontrollably adjust the rate at which web 120 is heated and/or cooled indrying system 140.

Although specific embodiments were described herein, the scope of theinventive concepts is not limited to those specific embodiments. Thescope of the inventive concepts is defined by the following claims andany equivalents thereof.

We claim:
 1. An apparatus comprising: first rollers, at least one ofwhich is configured to conduct heat from a heat source, and to dry a webof print media as the web travels over a front side of the first rollersin a first direction, wherein a last roller of the first rollers turnsthe web in a second direction; and second rollers disposed a distanceabove the first rollers and configured to transport the web in thesecond direction; wherein the second rollers occupy spaces between thefirst rollers so that the web traveling in the second direction contactsa back side of the first rollers to further dry the web.
 2. Theapparatus of claim 1 wherein: the first direction and the seconddirection of the web are substantially opposite in direction.
 3. Theapparatus of claim 1 wherein: an unmarked side of the web contacts thefront side of the first rollers as the web travels in the firstdirection.
 4. The apparatus of claim 3 wherein: the unmarked side of theweb contacts the back side of the first rollers as the web travels inthe second direction.
 5. The apparatus of claim 1 wherein: a marked sideof the web contacts the second rollers as the web travels in the seconddirection.
 6. The apparatus of claim 1 wherein: the first rollers arepositioned in a semi-circular configuration so that the web travels inan arch that follows a semi-circular path in the first direction; andthe second rollers are positioned in a semi-circular configurationinside the semi-circular configuration of the first rollers.
 7. Theapparatus of claim 6 wherein: the second rollers are positioned in asemi-circular configuration inside the semi-circular configuration ofthe first rollers such that centers of the seconds rollers are abovecenters of the first rollers in a direction that is perpendicular to thefirst direction.
 8. The apparatus of claim 1 wherein: the first rollersare positioned in a spiral configuration so that the web travels in anarch that follows a spiral path in the first direction; and the secondrollers are positioned in a spiral configuration inside the spiralconfiguration of the first rollers.
 9. A system comprising: a dryer of aprint system comprising: first rollers configured to transport a web ofprint media along a first path, wherein at least one of the firstrollers is configured to heat the web to dry ink applied on the web; andsecond rollers configured to transport the web along a second path abovethe first path; wherein the second rollers are disposed in spacesbetween the first rollers and the web contacts the first rollers againas it travels along the second path.
 10. The system of claim 9 wherein:the first path comprises a semi-circular pattern; and the second pathcomprises a semi-circular pattern above the first path.
 11. The systemof claim 10 wherein: the semi-circular pattern of the second rollers isabove the semi-circular pattern of the first path such that centers ofthe seconds rollers are above centers of the first rollers in adirection that is perpendicular to the first path.
 12. The system ofclaim 10 wherein: the first path and the second path of the web aresubstantially opposite in direction.
 13. The system of claim 12 wherein:a last roller of the first rollers turns the web from the first path tothe second path.
 14. The system of claim 13 wherein: the last roller ofthe first rollers has a largest circumference among the first rollers.15. The system of claim 14 wherein: the last roller of the first rollersis heated.
 16. The system of claim 9 wherein: the first rollers havelarger circumferences than the seconds rollers.
 17. A dryer comprising:a thermally conductive roller configured to turn a direction of a web,and to heat ink applied to the web via a heated surface; first rollersconfigured to transport the web from an entrance of the dryer to thethermally conductive roller; and second rollers configured to transportthe web from the thermally conductive roller to an exit of the dryer;wherein the seconds rollers occupy spaces between the first rollers suchthat the web travels in an interleaving pattern while it is transportedby the second rollers.
 18. The dryer of claim 17 wherein: the firstrollers transport the web along a semi-circular path in which the webdoes not contact the second rollers; and the second rollers transportthe web along another semi-circular path in which the web contacts boththe second rollers and the first rollers.
 19. The dryer of claim 18wherein: the another semi-circular path comprises a zig-zag pattern theweb follows as it alternates contact with the first rollers and theseconds rollers.
 20. The dryer of claim 17 wherein: at least one of thefirst rollers is heated to substantially dry the ink on the web beforethe ink reaches the thermally conductive roller.